US6330802B1 - Refrigerant loss detection - Google Patents
Refrigerant loss detection Download PDFInfo
- Publication number
- US6330802B1 US6330802B1 US09/510,703 US51070300A US6330802B1 US 6330802 B1 US6330802 B1 US 6330802B1 US 51070300 A US51070300 A US 51070300A US 6330802 B1 US6330802 B1 US 6330802B1
- Authority
- US
- United States
- Prior art keywords
- refrigerant
- charge
- compressor
- set forth
- evaporator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00642—Control systems or circuits; Control members or indication devices for heating, cooling or ventilating devices
- B60H1/00978—Control systems or circuits characterised by failure of detection or safety means; Diagnostic methods
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/32—Cooling devices
- B60H1/3204—Cooling devices using compression
- B60H1/3225—Cooling devices using compression characterised by safety arrangements, e.g. compressor anti-seizure means or by signalling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B49/00—Arrangement or mounting of control or safety devices
- F25B49/005—Arrangement or mounting of control or safety devices of safety devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2500/00—Problems to be solved
- F25B2500/22—Preventing, detecting or repairing leaks of refrigeration fluids
- F25B2500/222—Detecting refrigerant leaks
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/19—Pressures
- F25B2700/195—Pressures of the condenser
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/21—Temperatures
- F25B2700/2117—Temperatures of an evaporator
- F25B2700/21174—Temperatures of an evaporator of the refrigerant at the inlet of the evaporator
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/21—Temperatures
- F25B2700/2117—Temperatures of an evaporator
- F25B2700/21175—Temperatures of an evaporator of the refrigerant at the outlet of the evaporator
Definitions
- the subject invention relates to a method for detecting a loss of refrigerant in a vehicle air conditioning system.
- Air conditioning systems for motor vehicles typically include a refrigerant circuit having a compressor, a condenser, an evaporator, an accumulator, and a compressor.
- the compressor includes a motor for circulating the refrigerant through the circuit.
- the refrigerant often includes a lubricating oil for lubricating the compressor during operation. The compressor can overheat and bum out if the refrigerant and the lubricating oil become depleted.
- Heavy duty trucks require durable air conditioning systems for cooling the operator cabin. These air conditioning systems are required to operate consistently over hundreds of thousands of miles. To meet this requirement, a loss of refrigerant from the circuit must be identified before the compressor can be damaged from low refrigerant. Therefore, a need exist for accurately detecting a change in refrigerant level within the circuit before the compressor can be damaged from low levels of refrigerant.
- the Blair et al patent discloses an apparatus for detecting a partial loss of a refrigerant fluid by measuring the temperature difference of the refrigerant fluid between an evaporator inlet and an evaporator outlet. A controller measures the temperature difference against a predetermined value and interrupts power to compressor at a low refrigerant charge.
- the Blair patent discloses an apparatus for detecting a low refrigerant level by calculating saturation temperature of the refrigerant by measuring temperature and pressure in the gas phase between the compressor and the condenser.
- a third alternative disclosed in the Blair et al patent includes a pressure switch, which is located between the accumulator and the compressor. A clutch is cycled at preset low and high pressures of refrigerant as measured in the gas phase between the accumulator and the compressor.
- the disclosed concepts provide protection for the compressor, several shortcomings exist.
- the superheat calculation requires significant computer resources due to the complexity of the calculation.
- simply determining the temperature difference between the inlet and the outlet of the evaporator without more, can give inaccurate superheat readings reducing the effectiveness of the system.
- no provisions are made for determining partial loss of refrigerant, which would ultimately lead to required maintenance, but would allow continued operation of the air conditioning system.
- measuring the refrigerant pressure in the gas phase has not proven to be an accurate indicator of low refrigerant charge at broad ranges of ambient temperatures.
- a method for refrigerant loss detection that would both provide a visual signal of refrigerant charge and terminate power to the compressor upon critically low refrigerant charge would be preferable to the prior art.
- the subject invention provides a method for detecting a low level of refrigerant circulating through a motor vehicle refrigerant circuit having a compressor, a condenser, an evaporator, and an accumulator.
- the method includes detecting a partial loss of a refrigerant fluid by measuring the temperature difference of the refrigerant fluid between an evaporator inlet and an evaporator outlet, and is characterized by detecting a complete loss of refrigerant by measuring the pressure of the refrigerant in the liquid phase between the condenser and the evaporator.
- a visible signal can be provided before the refrigerant falls to a level that requires power to the compressor be terminated for preventing the compressor from being damaged. This allows for maintenance to be scheduled rather than having emergency repairs performed while in route.
- a simple algorithm can be developed to accurately measure refrigerant loss while not utilizing significant amount of computer resources.
- measuring the refrigerant pressure in the liquid phase eliminates the need for performing a superheat calculation. By eliminating the superheat calculation, a control algorithm can be developed that is simplified. This provides more consistent outputs from the algorithm at a broader range of ambient temperatures thereby providing more consistent measurements of refrigerant charge level.
- FIG. 1 is a schematic view of the subject invention for detecting a low level of a refrigerant circulating through an air conditioning system having an orifice tube based apparatus represented as a throttling device known as a CCOT system.
- FIG. 2 is a schematic view of an alternative embodiment of the subject invention having a thermostatic expansion valve based apparatus represented as a receiver/dryer known as a CCTXV system.
- FIG. 1 a schematic view is generally shown at 10 of an apparatus for detecting a low level of refrigerant circulating through a motor vehicle refrigerant circuit having a compressor 12 , a condenser 14 , an evaporator 16 , and an accumulator 18 .
- a throttling device 19 is positioned between the condenser 14 and the evaporator 16 .
- the throttling device 19 comprises an orifice tube as is known in the art.
- the compressor 12 includes a clutch 20 for activating and deactivating the compressor 12 .
- the apparatus 10 includes an inlet thermistor 22 located in the refrigerant circuit proximate an inlet of the evaporator 16 and an outlet thermistor 24 located in the circuit proximate an outlet of the evaporator 16 .
- the thermistors 22 , 24 are in communication with a controller 26 for relaying to the controller 26 temperature measurements of the refrigerant.
- the controller 26 is in communication with a display panel 28 for providing a visual signal in response to the comparison between a calculated charge index and a predetermined charge index.
- the visual signal displays a service soon signal 30 for indicating a partial loss of refrigerant and a service now signal 32 for indicating a critical loss of refrigerant. This communication may also be transmitted digitally on a vehicle multiplexing bus (not shown).
- a pressure transducer 34 is located in the circuit between the condenser 14 and the evaporator 16 for measuring the pressure of the refrigerant in the liquid phase. More specifically, the pressure transducer 34 is located between the condenser 14 and the throttling device 19 . The pressure transducer is in communication with the controller 26 for relaying pressure measurements to the controller 26 .
- FIG. 2 An alternate embodiment of the subject invention is shown in FIG. 2 having a compressor 12 , a condenser 14 , a receiver-dryer 35 , a thermal expansion valve 37 , and an evaporator 16 .
- the thermal expansion valve 37 is disposed between the receiver-dryer 36 and the evaporator 16 .
- the pressure transducer 34 is located between the condenser 14 and the receiver-dryer 36 .
- the method for determining refrigerant loss is identical for both embodiments.
- Inputs from the thermistors 22 , 24 and the pressure transducer 34 are filtered and converted to engineering units by the controller 26 at least two times per second. Transients are removed by converting the measurement to engineering units with the following algorithm:
- the controller 26 is contemplated to be an 8-bit micro controller that can interface with a CAN, J1939, or a J1708/J1587 bus. This allows, the controller 26 to communicate with the display panel 28 , which is located in a cab of a heavy duty truck, or a passenger compartment of a light vehicle through an existing vehicle electronic system. However, the communication busses mentioned above are not required for operation.
- the refrigerant charge index is developed from the following algorithm:
- Ci n ⁇ T+(1 ⁇ )Ci n ⁇ 1
- the charge index is recalculated every thirty seconds if the compressor 12 is running continuously. Otherwise, the charge index is refreshed immediately after the compressor 12 is cycled off.
- a predetermined charge index table having a plurality of charge indexes is stored within the controller 26 .
- Each charge index corresponds to a separate range of ambient air temperatures.
- the range of ambient air temperature is separated into three operating conditions. The first range is an extreme operating condition of temperatures over 110° F.
- the second range is a normal operating condition of temperatures between 85° F. and 110° F.
- the third range is a cold operating condition of temperatures below 70° F.
- Each of the ambient temperature ranges includes a predetermined medium charge index, a predetermined low charge index, and a predetermined very low charge index.
- the various charge indexes can be adjusted to meet the operating specifications of a particular refrigerant circuit.
- a service now indicator will also signal the logics not to power up the compressor 12 , thus protecting it from operating in a dangerous mode.
- the calculated charge index is compared with a predetermined medium charge index and a predetermined low charge index. If the calculated charge index is greater than or equal to the predetermined medium charge index and less than the predetermined low charge index and a medium charge ten minute timer is not activated, the medium charge ten minute timer is activated. If the calculated charge index is less than the predetermined medium charge index and the medium charge timer is running, then the medium charge timer is reset. If the calculated charge index is greater than or equal to the predetermined medium charge index and the medium charge ten minute timer has expired, then a service soon indicator is activated on the display panel 28 and the medium charge timer is reset.
- the calculated charge index is compared with a predetermined low charge index and predetermined very low charge index. If the calculated charge index is greater than the predetermined low charge index and less than the predetermined very low charge index then a low charge, ten minute timer and a medium charge, ten minute timer is started. If the calculated charge index is less than the predetermined low charge index and the low charge timer is still running, then the low charge timer is reset to zero and a low charge counter is set to zero. If the calculated charge index is greater than the predetermined low charge index and less than the very low charge index, and the low charge timer has expired, and if the low charge counter is less than three, the low charge counter is incremented by one and the low charger timer is reset. Otherwise, the service soon notification provided as a visual signal on the display panel 28 will be deactivated, a service now indicator will be activated, and the low charge timer will be reset.
- the calculated charge index is compared with a predetermined very low charge index. If the calculated charge index is greater than or equal to the predetermined very low charge index and a very low charge timer is not activated, the very low charge timer is activated and the medium charge timer is activated. If the calculated charge index is less than the predetermined very low charge index and the very low charge timer is running then the very low charge timer is reset. If the calculated charge index is greater than or equal to the predetermined very low charge index and the very low charge timer has expired, then the service soon indicator will be deactivated, a service now indicator will be activated, and the low charge timer will be reset to zero.
- a complete loss of refrigerant is detected by measuring the pressure of the refrigerant in the liquid phase between the condenser 14 and the evaporator 16 . If the controller 26 detects a near zero pressure, the controller 26 will terminate power to the compressor clutch 20 and activate the service now notification. Additionally, the service now notification will be activated if pressure is below a predetermined low pressure and the outlet temperature is greater than a predetermined outlet temperature. If the pressure is greater than a predetermined high pressure, the service now indicator is activated. If the slope the curve of the temperature vs. time as the compressor 12 is cycled on is less than or equal to a predetermined slope, the service now indicator is activated. If the time between cycling the compressor 12 on and cycling the compressor 12 off is less than or equal to a predetermined time, the service now indicator is activated.
- the compressor clutch 20 is cycled in response to the refrigerant temperature at the evaporator 16 inlet. If the inlet temperature is less than or equal to a predetermined clutch 20 termination temperature, the clutch 20 is stopped, deactivating the compressor 12 . If the inlet temperature is greater than or equal to a predetermined clutch 20 activation temperature, the clutch 20 is started, activating the compressor 12 . The time the compressor 12 is cycled on, and the time the compressor 12 is cycled off, is stored by the controller 26 . The algorithm will utilize the time on and the time off to minimize rapid cycling of the compressor 12 by maintaining a consistent period of time between the time on and the time off and between the time off and the time on. By minimizing rapid cycling, the life span of the compressor 12 can be extended.
- the engine fan 36 pulls air across the condenser 14 and is cycled in response to the pressure of the refrigerant in the liquid phase. If the measured pressure is greater than or equal to a predetermined fan activation pressure, the engine fan 36 is activated. If the measured pressure is less than or equal to a predetermined deactivation pressure, the engine fan 36 is deactivated.
Abstract
Description
Claims (11)
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US09/510,703 US6330802B1 (en) | 2000-02-22 | 2000-02-22 | Refrigerant loss detection |
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US09/510,703 US6330802B1 (en) | 2000-02-22 | 2000-02-22 | Refrigerant loss detection |
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Cited By (39)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20020083723A1 (en) * | 2000-12-11 | 2002-07-04 | Walter Demuth | Method of monitoring refrigerant level |
WO2002042100A3 (en) * | 2000-11-27 | 2002-08-22 | Phil Trigiani | Method for diagnosing performance of air-conditioning systems |
US6463747B1 (en) * | 2001-09-25 | 2002-10-15 | Lennox Manufacturing Inc. | Method of determining acceptability of a selected condition in a space temperature conditioning system |
US20030182950A1 (en) * | 2002-03-26 | 2003-10-02 | Mei Viung C. | Non-intrusive refrigerant charge indicator |
US6629420B2 (en) * | 2000-07-31 | 2003-10-07 | North Europ Patents & Invest | Method and device for testing and diagnosing air-conditioning apparatus on vehicles |
WO2004005812A1 (en) * | 2002-07-08 | 2004-01-15 | Danfoss A/S | A method and a device for detecting flash gas |
US6708507B1 (en) | 2003-06-17 | 2004-03-23 | Thermo King Corporation | Temperature control apparatus and method of determining malfunction |
US6840053B2 (en) | 2003-01-27 | 2005-01-11 | Behr America, Inc. | Temperature control using infrared sensing |
US20050039469A1 (en) * | 2001-11-01 | 2005-02-24 | Hikaru Nonaka | Refrigerator |
US20050056031A1 (en) * | 2003-09-17 | 2005-03-17 | Lg Electronics Inc. | Refrigerant leakage sensing system and method |
US20050109050A1 (en) * | 2003-11-03 | 2005-05-26 | Laboe Kevin J. | Refrigerant charge level determination |
US20050126191A1 (en) * | 2003-12-10 | 2005-06-16 | Alexander Lifson | Diagnosing a loss of refrigerant charge in a refrigerant system |
US20050166608A1 (en) * | 2002-04-22 | 2005-08-04 | Danfoss A/S | Method for evaluating a non-measured operating variable in a refrigeration plant |
US20050172647A1 (en) * | 2002-04-22 | 2005-08-11 | Danfoss A/S | Method for detecting changes in a first flux of a heat or cold transport medium in a refrigeration system |
WO2005073645A1 (en) * | 2004-01-28 | 2005-08-11 | Bms-Energietechnik Ag | Highly efficient evaporation in refrigerating installations and corresponding method for obtaining stable conditions with minimal and/or desired temperature differences of the media to be cooled in relation to the evaporation temperature |
US20060021362A1 (en) * | 2004-07-28 | 2006-02-02 | Payman Sadegh | Charge loss detection and prognostics for multi-modular split systems |
US20060032606A1 (en) * | 2002-10-15 | 2006-02-16 | Claus Thybo | Method and a device for detecting an abnormality of a heat exchanger and the use of such a device |
US20060137367A1 (en) * | 2004-12-27 | 2006-06-29 | Carrier Corporation | Dual thermochromic liquid crystal temperature sensing for refrigerant charge indication |
US20060137364A1 (en) * | 2004-12-27 | 2006-06-29 | Carrier Corporation | Refrigerant charge adequacy gauge |
US7610765B2 (en) | 2004-12-27 | 2009-11-03 | Carrier Corporation | Refrigerant charge status indication method and device |
GR1006642B (en) * | 2008-07-14 | 2009-12-22 | Θεοδωρος Ευθυμιου Ευθυμιου | Automatic refrigerant leak detection system of indirect means for use on cooling and refrigerations units installed on vehicles and other transportation means. |
WO2010037464A1 (en) * | 2008-10-01 | 2010-04-08 | Bayerische Motoren Werke Aktiengesellschaft | Method for controlling or regulating a vehicle air conditioning system |
US20100088046A1 (en) * | 2006-12-20 | 2010-04-08 | Carrier Corporation | Method for determining refrigerant charge |
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US20130002446A1 (en) * | 2011-06-29 | 2013-01-03 | Smith Mark G | Low air conditioning refrigerant detection method |
US20130167567A1 (en) * | 2010-10-14 | 2013-07-04 | Mitsubishi Electric Corporation | Refrigeration cycle apparatus |
US8943846B1 (en) | 2013-08-21 | 2015-02-03 | Red Dot Corporation | Electronic thermostat |
US20150107278A1 (en) * | 2012-03-09 | 2015-04-23 | Halla Visteon Climate Control Corporation | Device And Method For Icing Prevention Regulation For Heat Pump Evaporators |
US20160091241A1 (en) * | 2013-08-26 | 2016-03-31 | Mitsubishi Electric Corporation | Air-conditioning apparatus and refrigerant leakage detection method |
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US9568226B2 (en) | 2006-12-20 | 2017-02-14 | Carrier Corporation | Refrigerant charge indication |
US9759465B2 (en) | 2011-12-27 | 2017-09-12 | Carrier Corporation | Air conditioner self-charging and charge monitoring system |
US20180119685A1 (en) * | 2010-06-30 | 2018-05-03 | Hyundai Motor Company | Device and method for controlling compressor of vehicles to accumulate cold air energy in an evaporator during a speed-reducing condition and using the latter in a release condition |
JP2018146159A (en) * | 2017-03-03 | 2018-09-20 | 日立ジョンソンコントロールズ空調株式会社 | Air conditioner |
EP3255360B1 (en) | 2016-06-08 | 2018-11-14 | Truma Gerätetechnik GmbH & Co. KG | Air conditioning system and method for leakage detection in an air conditioning system |
CN110160208A (en) * | 2019-05-27 | 2019-08-23 | 广东美的制冷设备有限公司 | Air conditioner and the secondary refrigerant leakage detection method of air conditioner, device |
WO2019166881A3 (en) * | 2019-06-07 | 2020-07-16 | الزيتوني خيري، | Refrigerating circuit comprising electromagnetic valves upstream and downstream of each component of the circuit, allowing refrigerant leaks to be prevented |
US11022346B2 (en) | 2015-11-17 | 2021-06-01 | Carrier Corporation | Method for detecting a loss of refrigerant charge of a refrigeration system |
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Title |
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"A Microprocessor Controller and Sensor for Refrigerant Low Charge Detection in an Air Conditioning System" Presented Dec. 4-6, 2000 Derek Y. Kamemoto, Peder L. Hamberg and Gary P. Hansen Red Dot Corporation 2000-01-3444. |
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